Service Manual

CONTENTS
SERVICING
1. TROUBLESHOOTING ......................................................................................S-1
2. SERVICING SPECIFICATIONS ......................................................................S-4
3. TIGHTENING TORQUES ..............................................................................S-11
[1] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS
AND NUTS...............................................................................................S-11
[2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS
AND NUTS...............................................................................................S-12
4. CHECKING, DISASSEMBLING AND SERVICING......................................S-13
[1] CHECKING AND ADJUSTING ...............................................................S-13
(1) Engine Body........................................................................................S-13
(2) Lubricating System .............................................................................S-15
(3) Cooling System...................................................................................S-15
(4) Fuel System ........................................................................................S-17
(5) Electrical System ................................................................................S-21
[2] DISASSEMBLING AND ASSEMBLING..................................................S-28
(1) Draining Engine Oil and Coolant.........................................................S-28
(2) External Components .........................................................................S-29
(3) Cylinder Head, Valves and Oil Pan.....................................................S-29
(4) Gear Case and Timing Gears .............................................................S-35
(5) Piston and Connecting Rod ................................................................S-42
(6) Flywheel and Crankshaft ....................................................................S-45
(7) Starter .................................................................................................S-49
(8) Dynamo...............................................................................................S-51
(9) Alternator ............................................................................................S-52
[3] SERVICING ..............................................................................................S-53
(1) Cylinder Head and Valves ..................................................................S-53
(2) Timing Gears ......................................................................................S-59
(3) Piston and Connecting Rod ................................................................S-61
(4) Crankshaft...........................................................................................S-64
(5) Cylinder...............................................................................................S-70
(6) Oil Pump .............................................................................................S-71
(7) Starter .................................................................................................S-72
(8) Alternator ............................................................................................S-75
KiSC issued 03, 2011 A